Relay module and electrical component unit

ABSTRACT

There is provided a relay module including: a power lead part connected to a power source; a connector lead part connected to a load; a relay switch interposed between the power lead part and the connector lead part, and electrically connected thereto; a control member for controlling the relay switch; and a molded part sealing at least ends of the power lead part and the connector lead part near the control member, the relay switch, and the control member.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based on Japanese Patent Application No.2005-309500, the contents of which are hereby incorporated by reference.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates to a relay module and an electricalcomponent unit, in particular, to a relay module using a relay switchfor supplying electric power to a load, and an electrical componentunit.

2. Description of the Related Art

As an electrical component unit on a vehicle using a semiconductor relaysuch as an intelligent power switch (IPS), a unit having a control boardon which a connector and a semiconductor relay are packaged is wellknown. The connector connects the load such as a headlamp, a fog lamp,and various motors to the control board. The semiconductor relaysupplies the electric power to the load corresponding to an instructionfrom the control board.

Such an electrical component unit on a vehicle is disclosed in JapanesePatent Application No. 2002-293201. The electrical component unit on avehicle receives the control board and a semiconductor relay modulepackaged on the control board in a case main body, and a cover coversthe case main body. Regarding the semiconductor relay module, thesemiconductor relay is bonded to a die pad, and molded integrally with alead wire connected to the control board, a lead wire for the connector,and a lead wire for a battery. The semiconductor relay module andelectronic parts for controlling the semiconductor relay module arepackaged on the control board.

However, according to the electrical component unit on a vehicledescribed above, the control board is separated into a power part wherethe semiconductor relay module is packaged and a control part where theelectronic parts are packaged. Therefore, a packaging area and apackaging volume on the control board are increased. A useless space isgenerated at the control part. Thus, the electrical component unit tendsto be upsized. In such a configuration, because the number of parts islarge, an assembling structure is complex, and a packaging processwastes time.

Accordingly, an object of the present invention is to provide a relaymodule and an electrical component unit that is able to be downsized,and save weight.

SUMMARY OF THE INVENTION

In order to attain the object, according to the present invention, thereis provided a relay module including:

a power lead part connected to a power source;

a connector lead part connected to a load;

a relay switch interposed between the power lead part and the connectorlead part, and electrically connected thereto;

a control member for controlling the relay switch; and

a molded part sealing at least ends of the power lead part and theconnector lead part near the control member, the relay switch, and thecontrol member.

According to another aspect of the present invention, there is providedan electrical component unit including:

a relay module described above;

a connector connected to a wire from a load; and

a receiving chamber for receiving the relay module and the connector,said relay module and the connector are electrically connected.

These and other objects, features, and advantages of the presentinvention will become more apparent upon reading of the followingdetailed description along with the accompanied drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an exploded perspective view showing an electric coupling boxreceiving relay blocks;

FIG. 2 is an exploded perspective view of the relay block in FIG. 1;

FIG. 3 is a perspective view showing an outline structure of a relaymodule according to the present invention;

FIG. 4 is an equivalent circuit diagram of the relay module in FIG. 3;

FIG. 5 is an explanatory view showing how the relay block is received inthe electric coupling box;

FIG. 6A is an explanatory view showing how the relay module is assembledwith a case main body;

FIG. 6B is an explanatory view showing how the relay module is assembledwith a block member; and

FIG. 6C is an explanatory view showing a finish of the assembling.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS First Embodiment

A first embodiment of an electric coupling box 1 including a relaymodule and an electrical component unit according to the presentinvention will be described with reference to FIGS. 1 to 4.

As shown in FIG. 1, the electric coupling box 1 includes a box main body2 having a substantially rectangular tray shape, a cover 3 covering anupper opening of the box main body 2, and a plurality of relay blocks 10as the electrical component units. The box main body 2 includes aplurality of installation parts 4 for electric parts such as relayblocks 10 and relays 20 at an upper side thereof. The box main body 2includes another installation parts (not shown) for connectors 30connected to wires from loads at a lower side thereof, where theconnectors 30 are electrically connected to the electric parts installedon the installation parts 4. The box main body 2 and the installationparts are integrally molded with insulating synthetic resin. A throughhole for a lead wire is formed on the installation parts 4 for allowingthe lead part of the electric part to project from a specific position.

As shown in FIG. 2, the relay block 10 includes a case main body 11having a substantially rectangular tray shape, a cover 12 covering thecase main body 11, and a relay module 40. The case main body 11 and thecover 12 are made of insulating synthetic resin. The case main body 11includes an installation part (not shown) for installing the relaymodule 40 of the present invention. A through hole is formed on theinstallation part for allowing the lead part of the relay module 40 toproject from a specific position of the installation part.

Incidentally, in this first embodiment, the one relay block 10 receivesthe one relay module 40. However, the relay block may receive aplurality of relay modules 40. In this case, a plurality of installationparts is formed on the relay block 10, and a size of the relay block 10is changed.

As shown in FIGS. 3 and 4, the relay module 40 includes power lead parts41A, 41B for connected to a power source, a plurality of connector leadparts 42 for connected to loads L1, L2, L3, L4, a semiconductor relayswitches 43A, 43B interposed between and electrically connected to thepower lead parts 41A, 41 b and the connector lead parts 42, a controlunit 44 for controlling the semiconductor switches 43A, 43B, and amolding part 47 at least sealing ends near the control unit 44 of thepower lead parts 41A, 41B, and connector lead parts 42, thesemiconductor relay switches 43A, 43B, and the control unit 44.

Each of the power lead parts 41A, 41B is installed on the relay block10. Then, the relay block 10 is installed on the electric coupling box 1and the power lead parts 41A, 41B are inserted into holes of a connector30 and connected to terminals of the connector 30 so that the power leadparts 41A, 41B are connected to the power source through wires connectedto the terminals.

Each of the connector lead parts 42 is installed on the relay block 10.Then, the relay block 10 is installed on the electric coupling box 1 andthe connector lead parts 42 are inserted into the insertion holes of theconnector 30 to be connected to the terminals of the connector 30. Thus,the connector lead parts 42 are electrically connected to the loads L1,L2, L3, L4 which for example drives a headlamp, or a motor for driving awiper through wires connected to the terminals.

The power lead parts 41A, 41B and the connector lead parts 42 are madeof metal plate such as aluminum, copper, copper-iron alloy,copper-iron-phosphorus alloy, copper-chromium alloy,copper-nickel-silicon alloy, copper-tin alloy, nickel-iron alloy,iron-nickel-cobalt alloy, copper-stainless steel alloy. Further,nickel-plated, silver-plated, or gold-plated metal plate is acceptable.

Further, because high current flows through the power lead parts 41A,41B and the connector lead parts 42, the widths thereof are wide.Electric power is supplied to the connector lead parts 42 from the powerlead parts 41A, 41B corresponding to switching operation of thesemiconductor relay switches 43A, 43B.

An intelligent power switch, MOSFET (metal oxide silicon field effecttransistor), or the like is used for the semiconductor relay switches43A, 43B and installed on surfaces of the power lead parts 41A, 41B.Because drain electrodes as backside electrodes are electricallyconnected to die pads 41C of the power lead parts 41A, 41B, currentcapacities are relatively greater than those of surface electrodes ofthe semiconductor relay switches 43A, 43B and the high current can flowthrough the power lead parts 41A, 41B.

Incidentally, in the first embodiment, the semiconductor relay is usedas a relay switch. However, the present invention is not limited tothis. Various relays such as a mechanical relay or a hybrid relay can beused.

The control unit 44 includes a control member 44 a having an MPU(microprocessor unit), an LSI (large-scale integrated circuits) and thelike, and a control board 44 b having the control member 44 a andelectric parts.

The control member 44 a is electrically connected to gate electrodes ofthe semiconductor relay switches 43A, 43B, and controls the switchingoperations of the semiconductor relay switches 43A, 43B by outputtinghigh/low signals as control signals to the gate electrodes.

The control board 44 b includes a surface electrode 44 c and a surfaceelectrode at the connector side 44 d. The surface electrode 44 c andsource electrodes of the semiconductor relay switches 43A, 43B arewire-bonded and electrically connected to each other. Similarly, thesurface electrode at the connector side 44 d and the connector leadparts 42 are wire-bonded and electrically connected to each other. Thesurface electrode 44 c at the power lead part 41A side is electricallyconnected to the surface electrode at the connector side 44 d by wiringpatterns branching to the loads L1, L2 to which the semiconductor relayswitch 43A supplies the power. Also, the surface electrode 44 c at thepower lead part 41B side is electrically connected to the surfaceelectrode at the connector side 44 d by wiring patterns branching to theloads L3, L4 to which the semiconductor relay switch 43B supplies thepower.

According to such a configuration of the control board 44 b, a powersupplying line is formed for supplying the loads L1, L2, L3, L4respectively through the connector lead parts 42 from the semiconductorrelay switches 43A, 43B corresponding to the switching operations of thesemiconductor relay switches 43A, 43B controlled by the control member44 a.

Incidentally, aluminum wire, gold wire, copper wire, or a ribbon ofthose can be used as a bonding wire connecting the power lead parts 41A,41B and the control unit 44, the control unit 44 and the connector leadparts 42.

According to the first embodiment, a control unit having the controlboard 44 b on which the control member 44 a is installed is mounted on aplate-shaped frame member 46. However, if the control member 44 a can bedirectly wire-bonded to the power lead parts 41A, 41B, the connectorlead parts 42, and the semiconductor relay switches 43A, 43B, thecontrol board 44 b is not required.

In the molding part 47, ends of the power lead parts 41A, 41B and theconnector lead parts 42 near the control unit 44, the semiconductorrelay switches 43A, 43B, and the control unit 44 are plastic-molded in asubstantially box shape. Namely, the power lead parts 41A, 41B and theconnector lead parts 42 are extended from one sidewall of the moldingpart 47.

Thus, an outside shape of the relay module 40 is composed of an outsideshape of the molding part 47, the power lead parts 41A, 41B and theconnector lead parts 42 extended from the molding part 47, and thecontrol unit 44 is molded in the molding part 47. Therefore, it is notnecessary that the relay module 40 is installed on a substrate andreceived in a case member. Therefore, the relay module 40 can bedownsized and save weight.

Next, a forming of the relay module 40 will be explained. First, powerlead parts 41A, 41B, four connector lead parts 42, a lead member 46 usedfor the relay module 40 are formed in a lead frame in a specific shapeby stamping, etching or the like. Then, the semiconductor relay switches43A, 43B are respectively installed on the die pads of the lead frame.The control unit 44 is installed on the lead member 46. Thesemiconductor relay switches 43A, 43B and the control unit 44, thesemiconductor relay switches 43A, 43B, and the lead member 46 arerespectively wire-bonded. After the molding part 47 is formed on thelead frame by such as a transfer mold, extra parts of the lead breaksare cut. Thus, the relay module 40 is formed.

Next, an installation example of the relay module 40 and the relayblocks 10 to the electric coupling box will be explained with referenceto FIGS. 1 and 2.

As shown in FIG. 2, the relay module 40 is installed on the installationpart of the case main body 11, and the cover 12 covers the case mainbody 11, so that the relay module 40 is received and fixed to aninterior of the relay block 10. Thus, the relay module installationprocess is simple and time for the installation can be reduced.

As shown in FIG. 1, two relay blocks 10 are installed on theinstallation parts 4 of the box main body 2, and the cover 3 covers thebox main body 2, so that the two relay blocks 10 are received and fixedto an interior of the electric coupling box 1. The connectors 30connected to the wires from the loads are installed on the connectioninstallation parts from a lower side of the electric coupling box 1.Thus, the connectors 30 and the relay modules 40 are electricallyconnected to each other, and the connector lead parts 42 and the loadsL1, L2, L3, L4 are electrically connected to each other through thewires connected to the connectors 30.

When supplying the power to the loads L1, L2, the control member 44 a ofthe control unit 44 switches on the semiconductor relay switch 43A andthe power is supplied to the loads L1, L2 through the semiconductorrelay switch 43A from the power lead part 41A. Similarly, when supplyingthe power to the loads L3, L4, the control member 44 a of the controlunit 44 switches on the semiconductor relay switch 43B and the power issupplied to the loads L3, L4 through the semiconductor relay switch 43Bfrom the power lead part 41B.

According to the relay module 40 of the first embodiment, the moldingpart 47 seals the ends of the power lead parts 41A, 41B, connector leadparts 42 near the control member 44 a, the semiconductor relay switches43A, 43B, and the control member 44 a. Therefore, no useless space suchas a control board is generated. Therefore, the relay module 40 can bedownsized, and save weight. Further, because a member for connecting theconventional relay module and the control board is not required, cost ofthe relay module 40 can be reduced.

Further, according to the electronic component unit of the firstembodiment, because using the downsized, light-weighted relay module 40,the relay block 10 can be downsized, and save weight. Further, becausethe relay module 40 is downsized and light-weighted, a larger number ofrelay modules 40 can be installed. Therefore, it makes easier toexchange the relay modules 40 when a design changes. Thus,maintenanceability of the relay module 40 can be improved.

Incidentally, if a plurality of or some kinds of control units 44 areplastic molded on the relay module 40, only the relay module 40, whichis required to change owing to the design change, can be changed.Therefore, the maintenanceability of the relay module 40 is furtherimproved.

Further, according to the first embodiment, the power lead parts 41A,41B and the connector lead parts 42 are extended from one side of themolding part 47. However, various forms can be used. For example, thepower lead parts 41A, 41B and the connector lead parts 42 are fullymolded so as to be electrically connected.

Further, according to the relay module 40 described above, the power issupplied to the loads through the two of connector lead parts 42 of eachof the power lead parts 41A, 41B. However, the present invention is notlimited to this. Various forms can be used. For example, the power leadparts 41A, 41B and the connector lead parts 42 are respectivelyconnected in one to one relationships. For another example, two of theconnector lead parts 42 are respectively connected to a power line and acontrol line.

Further, in the first embodiment, the semiconductor relay switches 43A,43B correspond to the two of power lead parts 41A, 41B. However, thenumber of those can be optionally set.

Second Embodiment

One embodiment of the box main body 2 including a relay block having therelay module 40 of the first embodiment and the conventional relay blockwill be explained.

In FIG. 5, the electric coupling box 1 includes the box main body 2, thecover 3 (see FIG. 1), and the relay block installed corresponding to aproduct or the conventional relay block 60.

The box main body 2 includes a plurality of installation parts 4 forelectric parts such as relay blocks 10 and relays 20 at an upper sidethereof. The box main body 2 includes another installation parts (notshown) for connectors 30 connected to wires from loads at a lower sidethereof, where the connectors 30 are electrically connected to theelectric parts installed on the installation parts 4. A through hole fora lead wire is formed on the installation parts 4 for allowing the leadpart of the electric part to project from a specific position.

As shown in FIG. 6A to 6C, the relay block 10 includes a block member 16formed corresponding to the shape of the installation parts 4 forconnecting to the installation parts 4 of the box main body 2, a covercase 17 to be installed on the block member for receiving the relaymodule 40, and the relay module 40.

The block member 16 and the cover case 17 are made of insulatingsynthetic resin. The block member 16 includes a plurality of insertionholes 16 a to which power lead parts 41A, 41B and the connector leadparts 42 are inserted, a fitting member 16 b into which the cover case17 is fitted, and an engaging member 16 c for engaging with an engagingmember (not shown) mounted on an inner wall of the installation part 4.

The cover case 17 includes a press-fitting part 17 a into which therelay module 40 is press-fitted, an extending part 17 b for coveringleads of the relay module 40 fitted into the press-fitting part 17 a,and fitted into the fitting member 16 b, and an identification part 17 cidentifying the relay module 40 to be press-fitted into thepress-fitting part 17 a.

The press-fitting part 17 a is formed in a shape to allow the relaymodule 40 to be press-fitted into the cover case 17 having asubstantially box shape. For preventing the relay module 40 from fallingout, a projection, a catch, or the like is formed in an interior of thepress-fitting part 17 a.

The extending part 17 b is extended from the press-fitting part 17 a tocover the leads of the relay module 40 fitted into the press-fittingpart 17 a. An interior of the extending part 17 b is formed in a shapeto allow the relay module 40 to pass through. Thus, the extending part17 b protects the leads of the relay module 40, so that a trouble thatthe leads are bent at assembling is prevented. Accordingly, handlingability at the assembling of the relay module 40 with the cover case 17is improved.

The identification part 17 c has a color corresponding to a duty ratioof the relay module 40 or a product number of the relay module 40.Regarding the color, various forms can be accepted. For example, thecolor is the same as a color of a material of the cover case 17.Alternatively, the color is the color painted on a whole or a part ofsurface of the cover case 17. Alternatively, the color is a color of alabel or the like stuck on the cover case 17. Thus, the identificationpart 17 c prevents workers from miss-assembling the relay module 40.

Next, an assembling example of the relay blocks 10 of the secondembodiment will be explained with reference to FIG. 6.

As shown in FIG. 6A, the relay module 40 is pressed into thepress-fitting part 17 a of the cover case 17 having the identificationpart 17 c corresponding to the relay module 40. Then, as shown in FIG.6B, the extending part 17 b is fitted into the fitting member 16 b, andthe leads of the relay module 40 are inserted into the insertion holes16 a. Thus, as shown in FIG. 6C, the relay blocks 10 is assembled. Then,the relay module 40 is fitted into and installed on the installationparts 4 of the box main body 2.

The conventional relay block 60 includes a case main body 61 and theblock member 16. The case main body 61 includes a control board having aconnector and a semiconductor relay. Similar to the relay block 10, thecase main body 61 is installed on the block member 16, and theconventional relay block 60 is assembled. Then, the conventional relayblock 60 is fitted into and installed on the installation parts 4 of thebox main body 2.

According to the relay blocks 10 of the second embodiment, because thedownsized, light-weighted relay module 40 is used, the relay block 10can be downsized and save weight. Further, because the relay module 40is downsized and light-weighted, a larger number of relay modules 40 canbe installed. Therefore, it makes easier to exchange the relay modules40 when a design changes. Thus, maintenanceability of the relay module40 can be improved.

Further, the block member 16 is used for the relay block 10 and theconventional relay block 60. Therefore, the box main body 2 and aproduction line work for common use. Therefore, cost of the product canbe reduced.

Although the present invention has been fully described by way ofexample with reference to the accompanying drawings, it is to beunderstood that various changes and modifications will be apparent tothose skilled in the art. Therefore, unless otherwise such changes andmodifications depart from the scope of the present invention hereinafterdefined, they should be construed as being included therein.

1. A relay module comprising: a power lead part connected to a powersource; a connector lead part connected to a load, and made of flat leadframes; a relay switch interposed between the power lead part and theconnector lead part, and electrically connected thereto, and mountedwithin the confines of the power lead part; a control member forcontrolling the relay switch; and a molded part, having side walls,sealing by having embedded in the molded part, at least ends of thepower lead part and the connector lead part, the relay switch, and thecontrol member, the ends being adjacent the relay switch and the controlmember with no electrical components disposed therebetween, with thepower lead and the connector lead extended from one same side wall ofthe molded part and the control unit molded and sealed therein, whereinthe control member and relay switch are respectively mounted on the flatlead frames.
 2. An electrical component unit comprising: a relay moduleas claimed in claim 1; a connector connected to a wire from a load; anda receiving chamber for receiving the relay module and the connector,said relay module and the connector are electrically connected.